Uncommon tests on Transformers which help in life prediction.

By: Narendra Duvedi

Executive Director
SAS Powertech P Ltd.
Pune India
Considerable portion of Electrical infrastructure Investment is always in Power transformers.
Power transformers are installed mostly at the entrance of electrical energy intake point of any
establishment. Any abnormalities in grid power first hit the power transformer. Unless the
application justifies commercially transformers are never used with redundancy. So transformer
failure although it is not very common, can trigger grinding halt for a working establishment.
Most of the time establishments have Diesel Generator set backups, but cost of energy generated
is almost two times the utility cost and standby generators may not be rated for continuous duty.
A well – designed transformer should handle the load, while maintaining its load side power
quality and voltage regulation within acceptable limits. Temperature rise also should be within
limit.
A well-designed and systematically Type tested transformer having gone through Routine
tests after manufacturing and also Pre commissioning tests after installation gives multiple
decades of trouble-free service provided Preventive maintenance and some special diagnostic
tests are carried out periodically during it’s working life and required maintenance is done
intime.
It is observed that transformers installed in medium and large substations of utility companies are
usually installed to cater expected loads for next 10 to 15 years – so most of the time they are
capable of handling current loads without any problem. The maintenance during working life of
these transformers usually depends upon culture of the organization.
The utility transformers catering to last mile residential and commercial loads in urban and semi
urban area usually are neglected and suffer maximum due to overloading, poor / no maintenance
etc.
Similarly, large corporate sector Industries usually have underloaded transformers. Many places
HOT Standby transformers are also seen, which are kept charged from primary but are not loaded.
Recently while auditing a chemical plant with 45MW running load, we came across almost
60MVA redundant capacity, causing more than 300KW no load loss, costing the company around
Rs.3 Crores a year.
Above discussion suggests that a periodic check on transformer loading, justification for input
supply redundancy and reshuffling of transformer loads and shutting down transformer which are
not required for longer time, helps in reduction in wastage of electricity. Another main concern
is to get 30 years plus working life from the transformer and predicting it’s deterioration to help
allowing retrofitting and maintenance expenses
.
The main issue about oil filled power transformers is, they can not be opened frequently for
assessing health of windings and health of insulation. There are specific tests like Magnetic
balance test, magnetizing current test, Dissolved Gas Analysis test, Furan test– which are not
commonly done but are very useful if done with defined periodicity and results are monitored
closely on “year on year” basis. Here is an attempt made to discuss some details about how these
tests are carried out and how the results are interpreted to know physical condition of transformer
windings and insulation.
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1 Magnetic Balance Test of Transformer
Magnetic balance test of transformer is conducted only on three-phase transformers to check the
magnetic circuit imbalance.
How is this test performed?
Three limbs of magnetic material are placed side by side in a transformer. One phase winding is
wound on each limb. The voltage induced in different phases depends upon the respective position
of the limb in the core. The voltage induced in different phases of a transformer in respect to
neutral terminals given in the table below.
1. Keep the tap changer in normal position and disconnect neutral from ground
2. Apply single phase 230 V AC supply across one winding terminal and neutral.
3. Measure the voltage in two other terminals with respect to neutral.
4. Repeat the test for each of the three phases.

R Y B

Measured / Applied RN YN BN
voltage between Volts Volts Volts
Supply to RN 230 170 60
Supply to YN 115 230 115
Supply to BN 60 170 230

Interpretation of test results.

This indicates that the transformer is magnetically balanced. If there is any inter-turn short circuit
that may result in the sum of the two voltages not being equal to the applied voltage.

2 Magnetizing Current Test of Transformer

Magnetizing current test of transformer is performed to locate defects in the magnetic core
structure, shift of winding position, failure in between turn insulation or problem in tap changers.
This may happen just after transportation from factory – loading / unloading etc. This can also
happen due to low impedance short circuit – very near to transformer. These conditions may
change magnetic circuit reluctance, and affect the current required to establish flux.
1. Keep the tap changer in the lowest position. Apply 415 V supply on the three-line terminals
2. Measure the supply voltage and current in each phase
3. Repeat the test with keeping tap changer in normal position
4. Repeat the test while keeping the tap at highest position
5. Compare the current with measured exciting current during factory testing or during previous
testing.
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6. If the test current is found within 25% of previous readings, usually the test is considered as
satisfactory.
7. If the current measured is much more than the previous readings, there are chances that there
is fault in the windings and needs further investigation for confirmation.

3 Furan Analysis Test

Mechanical properties like tensile strength of insulating paper are used to evaluate reliable life of
paper insulation. Measurement of Degree of Polymerization (DP) of paper insulation is used for
this prediction. Whenever the transformer is opened and detanked, such physical paper sample
can be taken but for in service transformers it is required to draw inferences from transformer oil
testing.
DP values of 150-250 are considered as end-of-life criteria for paper insulation; for values below
150, the paper is without mechanical strength. The results of this test will be a deciding factor in
rebuilding or scrapping a transformer. When a cellulose molecule de-polymerizes (breaks into
smaller lengths or ring structures), a chemical compound known as a furan is formed and it
suspends in transformer oil. Measurement of quantity and types of furans present in transformer
oil sample, the DP of paper insulation can be inferred. This also indicate abnormal stress in a
transformer. It may be intense, short duration overheating or prolonged moderate overheating.
Furan analysis can be used to confirm Dissolved Gas Analysis where carbon monoxide present
indicates problems with solid insulation. It has been shown that the amount of 2-furaldehyde in
oil (usually the most prominent component of paper decomposition) is directly related to the DP
of the paper inside the transformer. Paper in a transformer does not age uniformly and variations
are expected with temperature, moisture distribution, oxygen levels and other operating
conditions. The levels of 2-furaldehyde in oil relate to the average deterioration of the insulating
paper. Consequently, the extent of paper deterioration resulting from a "hot spot" will be greater
than indicated by levels of 2-furaldehyde in the oil. New Kraft paper has a DP in excess of 1200,
and paper with a DP of 200 or less is considered to be unfit.

Other Diagnostic Compounds The presence of phenols and cresols in concentrations greater than
1 ppm indicate that solid components containing phenolic resin (laminates, spacers, etc.) are
involved in overheating. The values can be optimistic if the oil has been regenerated within the
last two years. This data should be evaluated in conjunction with routine chemical analysis and
transformer history.

4 Dissolved gas analysis (DGA)

This test is the study of dissolved gases in transformer oil. Whenever a transformer undergoes
abnormal thermal and electrical stresses, certain gases are produced due to the decomposition of
the transformer oil. When the fault is major, the production of decomposed gases are significant
and are collected in Buchholz relay. But when abnormal thermal and electrical stresses are not
significantly high the gasses due to decomposition of transformer insulating oil will get enough
time to dissolve in the oil.
Hence by only monitoring the Buchholz relay it is not possible to predict the condition of the total
internal healthiness of electrical power transformer. That is why it becomes necessary to analyze
the number of different gasses dissolved in transformer oil in service. In a DGA test, the gases in
oil are extracted and analyzed to determine the quantity of gasses in a specific volume of oil. By
observing the percentages of different gasses present in the oil, you can predict the internal
condition of the transformer.

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Generally, the gasses found in the oil in service are hydrogen (H2), methane (CH4), Ethane
(C2H6), ethylene (C2H4), acetylene (C2H3), carbon monoxide (CO), carbon dioxide (CO2),
nitrogen (N2) and oxygen(O2). This test uses Vacuum Gas Extraction Apparatus and Gas
Chronographs. Using this apparatus, gasses are extracted from oil by stirring it under vacuum.
These extracted gasses are then introduced in gas Chronographs for measurement of each
component.
The experience shows that hydrogen and methane are produced in large quantity if the internal
temperature of power transformer rises up to 10Deg C to 300Deg C due to abnormal thermal
stresses. If the temperature goes above 300oC, ethylene (C2H4) is produced in large quantity. If
temperatures are higher than 700Deg C a large amount of hydrogen(H2) and ethylene(C2H4) are
produced. If during DGA test of transformer oil, CO and CO2 are found in large quantity it is
predicted that there is decomposition of proper insulation.
Below is a table derived from ANSI/IEEE. The suggested action levels for key gas concentrations
are also provided:

Key Gas concentration in PPM

Gas Normal Action Limits Fault prediction.
limits < >
Hydrogen H2 150 1000 Corona Arcing
Methane CH4 25 80 Sparking
Acetylene C2H2 15 70 Arcing
Ethylene C2H4 20 150 Severe Overheating
Ethane C2H6 10 35 Local overheating
Carbon Monoxide CO 500 1000 Severe Overheating
Carbon Dioxide CO2 10000 15000 Severe Overheating
Total combustibles 720 720 4630

It is recommended that these tests should be carried out every year or every two years and the
record of parameters should be maintained for comparative study. A careful analysis of this
comparison helps in deciding preventive maintenance schedules and arranging shutdown etc. It
is also observed that expenses of these tests are not prohibitive compared to their usefulness.

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